Brushless DC motor with stator teeth having multiple parallel sets of windings

ABSTRACT

A brushless direct-current (BLDC) motor includes a stator assembly and a rotor assembly including a rotor supporting permanent magnets rotatable relative to the stator assembly. The stator assembly includes a stator comprising a stator core and stator teeth radially extending from the stator core and defining slots therebetween. A first set of stator windings is wound on the stator teeth, and a second set of stator windings is also wound on the stator teeth such that, on each stator tooth, the first and second windings are provided in an electrically parallel configuration.

RELATED APPLICATION

This patent application claims the benefit of U.S. ProvisionalApplication No. 63/129,797 filed Dec. 23, 2020, which incorporatedherein by reference in its entirety.

FIELD

This disclosure relates to a brushless motor assembly for a rotary tool,and particularly to a brushless motor assembly with high power density.

SUMMARY

According to an embodiment of the invention, a power tool is providedincluding a housing and a motor disposed within the housing. The motorincludes a stator assembly and a rotor assembly including a rotorsupporting magnets rotatable relative to the stator assembly. In anembodiment, the stator assembly includes a stator comprising a statorcore and stator teeth radially extending from the stator core anddefining slots therebetween, a first set of stator windings wound on thestator teeth, and a second set of stator windings wound on the statorteeth such that, on each stator tooth, one of the first windings isprovided electrically in parallel to one of the second stator windings.

In an embodiment, the stator assembly further includes stator terminalsprovide between respective stator teeth in the circumferential directionof the stator.

In an embodiment, the first set of stator windings includes a firstwinding wound on a first stator tooth of the stator teeth and physicallycoupled to adjacent ones of the stator terminals on two circumferentialsides of the first stator tooth. In an embodiment, the second set ofstator windings includes a second winding wound on the first statortooth and physically coupled to the adjacent ones of the statorterminals on the two circumferential sides of the first stator tooth tocreate a parallel connection with the first winding on the first statortooth.

In an embodiment, the second winding is stacked on top of the firstwinding away from the stator core.

In an embodiment, the stator assembly includes an end insulator providedat an axial end of the stator to electrically insulate the stator fromthe first plurality of stator windings and the second plurality ofstator windings, the end insulator including one or more support membersto support the stator terminals relative to the stator assembly.

In an embodiment, the number of the stator windings equals the number ofthe stator teeth, which also equals the number of the plurality ofstator terminals.

In an embodiment, the first set of stator windings includes a firstmagnet wire that is securely routed in contact with the stator terminalsas it is guided between the stator teeth, and the second set of statorwindings includes a second magnet wire that is securely routed incontact with the stator terminals adjacent the first magnet wire as itis guided between the stator teeth.

In an embodiment, the stator core defines a first circular envelope andoutermost portions of the terminals define a second circular envelopethat is contained within the first circular envelope and has a smallerdiameter than the first circular envelope.

In an embodiment, a circuit board is provided adjacent an axial end ofthe stator assembly. In an embodiment, the circuit board is mounted onthe stator terminals.

In an embodiment, the stator assembly includes an end insulator providedat an axial end of the stator to electrically insulate the stator fromthe first plurality of stator windings and the second plurality ofstator windings, the end insulator including support members to supportthe stator terminals relative to the stator assembly along alongitudinal direction of the motor. In an embodiment, the circuit boardis mounted and fastened to the support members.

In an embodiment, the circuit board includes magnetic sensors arrangedto magnetically interface with the rotor assembly. In an embodiment, thecircuit board also includes conductive traces arranged to connect thestator terminals. In an embodiment, the conductive traces of the circuitboard facilitate a delta-parallel connection between phases of themotor.

In an embodiment, the power tool further includes a motor housing havinga substantially cylindrical body housing the stator assembly and aradial member extending inwardly from the cylindrical body to form asupport pocket for rotationally supporting the rotor assembly. In anembodiment, the circuit board is disposed between the radial member andthe stator assembly.

In an embodiment, a power terminal block is disposed on a rear surfaceof the circuit board and electrically coupled to the conductive tracesto supply electric power to the first and second sets of statorwindings.

In an embodiment, the radial member of the motor housing is in contactwith the rear surface of the circuit board and includes one or moreopenings through which the power terminal block is received.

In an embodiment, at least one radial plane intersects the supportpocket, the radial member, and the power terminal block.

In an embodiment, the first set of stator windings is wound using asingle continuous wire.

In an embodiment, the first set of stator windings and the second set ofstator windings are together wound using a single continuous wire.

In an embodiment, the first set of stator windings and the second set ofstator windings have the same number of turns corresponding to a torquerating of the motor.

In an embodiment, the above-described embodiments provide a BLDC motorin a power tool that has a ratio of motor size constant (Km) to anelectrical envelope of the motor of at least 820 N·m/√W per m{circumflexover ( )}3, more particularly at least 850 N·m/√W per m{circumflex over( )}3, more particularly at least 900 N·m/√W per m{circumflex over( )}3, more particularly at least 940 N·m/√W per m{circumflex over( )}3, more particularly at least 980 N·m/√W per m{circumflex over( )}3, and more particularly at least 1020 N·m/√W per m{circumflex over( )}3. The electrical envelope of the motor is defined as the volume ofthe motor in which electrical and electronic components of the motor,including Hall sensors, magnet wires, and magnets, and wire connections,are located. In an embodiment, a ratio of he motor size constant Km to amagnetic envelope of the motor is at least 810 N·m/√W, more particularlyat least 850 N·m/√W, more particularly at least 890 N·m/√W, moreparticularly at least 930 N·m/√W, and more particularly at least 970N·m/√W. The magnetic envelope of the motor is defined as the area of themotor in magnetic components of the motor, including magnet wires andmagnets, are located.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side cross-sectional view of a power tool, according to anembodiment.

FIG. 2 depicts a perspective view of a motor provided within the powertool, according to an embodiment.

FIG. 3 depicts a perspective exploded view of the motor including a fanmounted on a rotor shaft adjacent the motor.

FIGS. 4 and 5 respectively depict a side cross-sectional view and aperspective cross-sectional view of the motor, according to anembodiment.

FIG. 6 depicts an axial cross-sectional view of stator assembly androtor assembly of the motor, according to an embodiment.

FIG. 7 depicts an axial cross-sectional view of the stator assembly androtor assembly, according to an alternative embodiment.

FIG. 8 depicts a perspective view of the stator assembly alone withoutthe circuit board, according to an embodiment.

FIG. 9 depicts a perspective view of the stator assembly with thecircuit board mounted thereon, according to an embodiment.

FIG. 10 depicts a side partially exploded view of the stator assemblyand the circuit board, according to an embodiment.

FIGS. 11A through 11D depict various layers of the multi-layers circuitboard, according to an embodiment.

FIG. 12 depicts a circuit diagram of a parallel-delta configurationbetween the phases of the motor, according to an embodiment.

FIG. 13 depicts a partial perspective view of the stator assemblyfocusing on a single stator terminal disposed between two statorwindings, according to an embodiment.

FIG. 14A depicts a simple circuit diagram of the parallel sets of statorwindings, according to an embodiment.

FIG. 14B depicts a simple winding diagram of the parallel sets of statorwindings, according to an embodiment.

FIGS. 15A and 15B depict partial cross-sectional views of a stator slotin which stator windings are wound using 19 AWG and 21.5 AWG magnetwires respectively, according to an embodiment.

FIG. 16 depicts a partial axial view of the stator assembly, accordingto an embodiment.

FIG. 17 depicts a side view of the stator without the windings,according to an embodiment.

FIG. 18A depicts a side view of a conventional stator with a stator corehaving a uniform thickness of approximately 4.8 mm and stator teethhaving a thickness of approximately 6.4 mm, according an embodiment.

FIG. 18B depicts a side view of a stator similar to the stator of FIG.18A, having a stator core with a reduced uniform thickness ofapproximately 3.5 mm and stator teeth 214 having a thickness ofapproximately 6.4 mm, according to an embodiment.

FIG. 18C depicts a side view of side view of a stator similar to FIG.18B, having a stator core with a uniform thickness of approximately 3.5mm, but with stator teeth having a reduced thickness of approximately5.9 mm, according to an embodiment.

FIG. 18D depicts a cross-sectional view of magnet wires having anoptimized geometric layout for maximizing wire density of the statorwindings, according to an embodiment.

FIG. 18E depicts a side view of side view of a stator similar to FIG.18C but including a stator core and stator teeth shaped to improve wirelayout as shown in FIG. 18D in order to increase wire density of thestator windings, according to an embodiment.

FIG. 18F depicts a side view of side view of a stator corresponding toFIGS. 3-17 , according to an embodiment.

FIG. 19 depicts a comparative diagram showing the maximum power outputperforming of motor including a conventional stator, an embodiment of animproved stator interfacing a rotor having embedded magnets, and anembodiment of an improved stator interfacing a rotor havingsurface-mount magnets.

FIG. 20 depicts the side cross-sectional view of FIG. 4 , additionallydepicting motor magnetic length and electrical length, according to anembodiment.

FIG. 21 depicts a table summarizing the motor performancecharacteristics in comparison to examples of comparable conventionalmotors, according to an embodiment.

FIG. 22 depicts a perspective view of the motor assembly with thecircuit board having an alternative terminal arrangement, according toan embodiment.

FIG. 23 depicts a perspective view of the motor including the terminalarrangement of FIG. 22 , according to an embodiment.

FIG. 24 depicts a perspective view of the motor with a power modulemounted directed to the motor housing, according to an embodiment.

FIG. 25 depicts a partial perspective view of an electric edgerincluding the above-described motor and power module arrangement,according to an embodiment.

FIG. 26 depicts a partial perspective view of the electric edger with afront portion of its housing removed to expose the motor and the powermodule, according to an embodiment.

DETAILED DESCRIPTION

The following description illustrates the claimed invention by way ofexample and not by way of limitation. The description clearly enablesone skilled in the art to make and use the disclosure, describes severalembodiments, adaptations, variations, alternatives, and uses of thedisclosure, including what is presently believed to be the best mode ofcarrying out the claimed invention. Additionally, it is to be understoodthat the disclosure is not limited in its application to the details ofconstruction and the arrangements of components set forth in thefollowing description or illustrated in the drawings. The disclosure iscapable of other embodiments and of being practiced or being carried outin various ways. Also, it is to be understood that the phraseology andterminology used herein is for the purpose of description and should notbe regarded as limiting.

FIG. 1 is a side cross-sectional view of a power tool 10, according toan embodiment. In an embodiment, power tool 10 is provided including ahousing 12 having a gear case 14, a motor case 16, a handle portion 18,and a battery receiver 20. Power tool 10 as shown herein is an anglegrinder with the gear case 14 housing a gearset 22 that drives an outputspindle 24 arranged to be coupled to a grinding, sanding, or cuttingdisc (not shown, herein referred to as “accessory wheel”). It should beunderstood, however, that the teachings of this disclosure may apply toany other power tool including, but not limited to, a saw, drill,sander, impact driver, hammer drill, cutting tool, polisher, and thelike. Gearset 22 may operate the output spindle 24 at a 90-degree angleorientation or in a linear orientation.

In an embodiment, the motor case 16 attaches to a rear end of the gearcase 14 and houses a motor 100 operatively connected to the gear set 22.In an embodiment, the motor 28 is a brushless direct-current (BLDC)motor that rotatably drives a rotor shaft 102, which in turn rotatablydrives the output spindle 24 via the gearset 22.

In an embodiment, the handle portion 18 extends from a rear end of themotor case 16 and includes a trigger assembly 36 operatively connectedto a switch module 38 disposed within the handle portion 18, which is inturn coupled to a control module 40 disposed close to the batteryreceiver 20 for controlling the battery discharge and the operation ofthe motor 100. The battery receiver 20 is provided at a rear end of thehandle portion 18 for detachable engagement with a battery pack (notshown) to provide power to the motor 100.

In an exemplary embodiment, the battery pack may be a 60-volt maxlithium-ion type battery pack, although battery packs with other batterychemistries, shapes, voltage levels, etc. may be used in otherembodiments. In various embodiments, the battery receiver 20 and batterypack may be a sliding pack disclosed in U.S. Pat. No. 8,573,324, herebyincorporated by reference. However, any suitable battery receiver andbattery back configuration, such as a tower pack or a convertible20V/60V battery pack as disclosed in U.S. patent application Ser. No.14/715,258 filed May 18, 2015, also incorporated by reference, can beused. The present embodiment is disclosed as a cordless, battery-poweredtool. However, in alternate embodiments power tool can be corded,AC-powered tools. For instance, in place of the battery receiver andbattery pack, the power tool 10 include an AC power cord coupled to atransformer block to condition and transform the AC power for use by thecomponents of the power tools. Power tool 10 may for example include arectifier circuit adapted to generate a positive current waveform fromthe AC power line. An example of such a tool and circuit may be found inUS Patent Publication No. 2015/0111480, filed Oct. 18, 2013, which isincorporated herein by reference in its entirety.

In an embodiment, the control module 40 is electronically coupled to apower module 42 provided in this embodiment adjacent the motor 100 tocontrol flow of electric power to the motor 100. Power module 42 mayalternatively be provided as a part of the same package as the controlmodule 40 or disposed at a different location of the power tool. In anembodiment, the power module 42 includes six power switches (e.g., FETsor IGBTs) configured as a three-phase inverter switch. The controlmodule 40 controls a switching operation of the power module 42 toregulate a supply of power from the battery pack to the motor 100. Thecontrol module 40 uses the input from the switch module 38 to set atarget speed for the motor 100. When the trigger assembly 36 isreleased, in an embodiment, the control module 40 activates the low-sideswitches or the high-side switches of the power module 42 simultaneouslyfor regenerative electronic braking of the motor. A description of thepower and control modules and electronic braking of the motor can befound in US Patent Publication No. 2017/0234484, filed Feb. 10, 2017,which is incorporated herein by reference in its entirety.

FIG. 2 depicts a perspective view of the motor 100, according to anembodiment. FIG. 3 depicts a perspective exploded view of the motor 100including a fan 106 mounted on the rotor shaft 102 adjacent the motor100. FIGS. 4 and 5 respectively depict a side cross-sectional view and aperspective cross-sectional view of the motor 100, according to anembodiment. The motor 100 is discussed in detail herein with referenceto these figures.

In an embodiment, motor 100 includes a motor housing (or motor can) 110configured and shaped to house and support the motor 100 components. Inan embodiment, motor housing 110 includes a generally cylindrical body112 that includes an open end for receiving the motor 100 components. Onthe other end of the body 112, a series of radial members 114 areformed. Radial members 114 extend towards from the body 112 towards acentral bearing pocket 116. In this embodiment, radial members 114include a series of openings therebetween, though radial members 114 maybe alternatively with a primarily solid wall. In an embodiment, the body112 further includes a series of air gaps 118 in conjunction with theopenings. Air gaps 118 are formed between a series of legs 119 formed atthe end of the body 112 adjoining the radial members 114.

In an embodiment, motor 100 further includes a stator assembly 120 and arotor assembly 140. In an embodiment, stator assembly 120 is disposedoutside the rotor assembly 140, though many principles of thisdisclosure may also apply to an outer-rotor motor. In an embodiment,motor 100 further includes a circuit board 150 secured to an end of thestator assembly 120 inside the motor housing 110. These features aredescribed herein in detail.

FIG. 6 depicts an axial cross-sectional view of the stator assembly 120and rotor assembly 140, according to an embodiment. Referring to thisfigure, and with continued reference to FIGS. 3 and 4 , stator assembly120, in an embodiment, includes a stator 122 that is preferably made upof a series of laminations. The outer diameter (OD) of the stator 122 issized to be fixedly received within the body 112 of the motor housing110. The stator 122 includes a stator core (or back-iron) 124 and aseries of inwardly-projecting teeth 126 around which a series of statorwindings 128 are wound. Specifically, stator teeth 126 form a series ofslots 127 in between, and stator windings 128 are wound inside the slots127 around the respective stator teeth 126. The number of stator teeth126 and stator windings 128 may corresponding to the number ofelectronically commutated phases of the motor 100. In an embodiment,where motor 100 is a three-phase motor, six teeth 126 and six sets ofwindings 128 may be provided.

In an embodiment, rotor assembly 140 includes a rotor 142 that ispreferably made up on a series of laminations mounted on the rotor shaft102 and disposed within the stator assembly 140. In an embodiment, aseries of discrete permanent magnets 144 are embedded within the rotor142 in a N-S-N-S orientation extending along a longitudinal axis of therotor shaft 102. The magnetic interface between the magnets 144 and thestator windings 128, as phases of the motor 100 are sequentiallyenergized, cause rotation of the rotor assembly 140 within the statorassembly 120. In an embodiment, rotor 142 includes a series of humpedsurfaces 146 in-line with centers of the permanent magnets 144 for noiseand vibration reduction.

Referring back to FIGS. 2 and 3 , in an embodiment, air gaps 118 of themotor housing 110, together with the circuit board 150, form aperturesaround the stator assembly 120, allowing entry of ambient air into themotor 100 to cool the motor components. In an embodiment, air gaps 118of the motor housing 110 are substantially aligned with the statorwindings 128 and legs 119 of the motor housing 110 are substantiallyaligned with the stator terminals 170 to cover the stator terminals 170.

Referring back to FIGS. 4 and 5 , in an embodiment, rear end insulator130 and front end insulator 132 are disposed on axial ends of the stator122 to provide electrical insulation between the stator windings 128 andthe stator 122. In an embodiment, the rear and front end insulators 130and 130 include similar profiles (i.e., core, teeth and slots) as thestator 122 when viewed longitudinally and are mounted on the axial endsof the stator 122 prior to the winding process. In an embodiment, asdiscussed later below, rear end insulator 130 further includes featuresfor supporting a series of stator terminals 170 in the direction of thecircuit board 150.

In an embodiment, rear and front rotor bearings 147 and 148 are mountedon the rotor shaft 102, in this example on opposite sides of the rotor142, to provide radial and/or axial support for the rotor assembly 140relative to the power tool 10, the motor housing 110, and/or statorassembly 120. In the illustrated example, the rear bearing 147 isreceived within bearing pocket 116 of the motor housing 110 and frontbearing 148 is supported via a wall or support structure of the toolhousing 12. The rear and front rotor bearings 147 and 148 maintain asmall airgap round the rotor 142 relative to the stator 122 to allowrotation of the rotor 142 within the stator 122 while maintaining radialand axial structural support for the rotor assembly 140. In anembodiment, central opening 156 of the circuit board 150 has a greaterdiameter than the rear rotor bearing 147 so the rear rotor bearing 147can be passed through the central opening 156 and securely receivedwithin the bearing pocket 116 during the assembly process.

FIG. 7 depicts an axial cross-sectional view of the stator assembly 120and rotor assembly 140, according to an alternative embodiment. In thisembodiment, a permanent magnet ring 149 is surface mounted on the rotor142. Magnet ring 149 is either includes four magnet segments eachextending 90 degrees of angular distance and adjoining at a N-S-N-Sorientation. In an embodiment, this orientation reduces magnetic fluxleakage and increases the power output density of the motor incomparison to the embedded rotor magnet design of FIG. 6 .

FIG. 8 depicts a perspective view of the stator assembly 120 alonewithout the circuit board 150, according to an embodiment. FIG. 9depicts a perspective view of the stator assembly 120 with the circuitboard 150 mounted thereon, according to an embodiment. FIG. 10 depicts aside partially exploded view of the stator assembly 120 and the circuitboard 150, according to an embodiment. Circuit board 150 and itsmounting to the stator assembly 120 is described herein in detail withreference these figures and continued reference to FIGS. 3-5 .

In an embodiment, circuit board 150 (herein also referred to as Hallboard) is provided inside the motor housing 110 adjacent the axial endof the stator assembly 120 and sandwiched between the stator 120 and theradial members 114 of the motor housing 110. In an embodiment, circuitboard 150 is disc-shaped including a central opening 156 through whichthe rotor shaft 102 extends for piloting into the central bearing pocket116 of the motor housing 110.

In an embodiment, circuit board 150 includes one or more magnetic (Hall)sensors 151 that interact with the rotor assembly 140. Signals from theHall sensors 151 are used to detect the angular position of the rotorassembly 140. In an embodiment, Hall sensors 151 are positioned insufficiently close proximity to the rotor magnets to directly sense theangular position of the rotor 142 by sensing the magnetic flux of therotor magnets. Alternatively, in an embodiment, an additional sensemagnet ring (not shown) may be disposed on the rotor shaft 102 adjacenthe rotor 102 in close proximity to the Hall sensors 151. Additionally,in an embodiment, circuit board 150 includes conductive traces toconnect the stator windings 128 in a series and/or parallel and deltaand/or wye configuration.

In an embodiment, circuit board 150 includes a series of openings 164arranged close to the outer circumference arranged to receive ends ofstator terminals 170. Stator terminals 170, as described later indetail, are mounted on the rear end insulator 130 of the stator assembly120 between the respective stator windings 128 and connect to a frontsurface of the circuit board 150 (facing the stator assembly 120) toelectrically connect the stator windings 128 to the conductive traces ofthe circuit board 150. In an embodiment, openings 164 are conductivevias to facilitate electrical connection between the stator terminals170 and the metal traces and routings.

In an embodiment, circuit board 150 further includes a control terminalblock 152 that includes a ribbon connector for communicating with thecontrol module 40. The control terminal block 152 includes at leastthree signals from the Hall sensors 151. The circuit board 15 furtherincludes a power terminal block 154 for providing power from the powermodule 42 to the stator windings 128. In an embodiment, control terminalblock 152 and power terminal block 154 are mounted on a rear surface ofthe circuit board 150 (facing away from the stator assembly 120) onopposite sides of the central opening 156.

In an embodiment, as best shown in FIG. 9 , power terminal block 154includes a set of conductive terminals 158 (in this case three terminalscorresponding to the three phases of the motor 100), each extendingperpendicularly from the rear surface of the circuit board 150 andincluding an upper opening for soldering or weldment to a power wire(not shown). The power terminal block 154 further includes an insulatingmount 160 that is mounted on the rear surface of the circuit board 150and includes slots through which the conductive terminals 158 extendfrom the circuit board 150. The insulating mount 160 provides structuraland insulative support for the conductive terminals 158, preventing themfrom being inadvertently bent and encounter one another. In anembodiment, the insulating mount 160 includes one or more walls 162positioned between the adjacent conductive terminals 158 to ensure thatcontamination of the power terminal block 154 by metallic particulatedoes not create electrical shortage between the conductive terminals158.

In an embodiment, rear end insulator 130 of the stator assembly 120includes a series of axial support members 134 provided to support thestator terminals 170 in the axial direction of the motor 100. Each axialsupport member 134 includes two posts that form an opening in betweenfor securely receiving and supporting one of the stator terminals 170.In an embodiment, six axial support members 134 support six statorterminals 170 between the respective sets of stator windings 128.

In an embodiment, two or more (in this example, three) of the axialsupport members 134 include threaded openings 136. The circuit board 150is secured to the stator assembly 120 via a series of fasteners 166received through corresponding openings of the circuit board 150 intothe threaded openings 136 of the rear end insulator 130.

In an embodiment, referring to FIG. 5 , axial support members 134 aresized to maintain a minimum distance A between the stator windings 128and the circuit board 150, while ensuring that the Hall sensors 151 aremaintained at a maximum distance B from the rotor permanent magnets 144for direct-sensing of the permanent magnets 144, where A>=B. In anembodiment, distances A and B both fall in the range of 1 to 6 mm.

In an embodiment, referring to FIGS. 2 and 3 , radial members 114 of themotor housing 110 are disposed in contact with the rear surface of thecircuit board 150, with control and power terminals blocks 152 and 154being received through the openings between the radial members 114 to beaccessible for coupling with electrical connectors and wires outside themotor housing 110. In an embodiment, routing the stator windings 128 onthe same circuit board 150 as the Hall sensors 156, and placement of thecircuit board 150 inside the motor housing 100, significantly reducesthe overall size of the motor 100 assembly, thus increasing the poweroutput density of the motor 100.

In an embodiment, as stated above, control and power terminal blocks 152and 154 of the circuit board 150 are received between radial members 114of motor housing 110 to facilitate coupling with control and power cordsreceived from the control and power modules 40 and 42 of the power tool10. As such, in an embodiment, as best seen in FIG. 4 , at least oneradial plane exists that intersects the rear bearing 147 of the rotorshaft 102, the radial members 114 of motor housing 110, and control andpower terminals blocks 152 and 154 of the circuit board 150.

In an embodiment, as stated above, circuit board 150 includes conductivetraces to connect the stator windings 128 in a series and/or paralleland delta and/or wye configuration. In order to maximize the surfaceareas of the conductive traces in the circuit board 150, according to anembodiment, circuit board 150 is multi-layered printed circuit board, asdescribed here with reference to FIGS. 11A through 11D.

FIGS. 11A through 11D depict various layers of the multi-layers circuitboard 150, according to an embodiment. In an embodiment, as shown inFIG. 11A, Hall sensors 151 are mounted on a front surface of the circuitboard 150. In an embodiment, as shown in FIGS. 11B-11D, conductive trace153 (electrically connecting U and U′ terminals), conductive trace 155(electrically connecting V and V′ terminals), and conductive trace 157(electrically connecting W and W′ terminals), are disposed on variousinner layers of the circuit board 150. In an embodiment, each of theconductive routings 153, 155 and 157 occupies approximately 90% or moreof the total surface area of the circuit board 150, thus reducing heatand resistance associated with the conductive traces.

In an embodiment, conductive traces 153, 155 and 157 are respectivelyconnected to U, V and W conductive terminals 158. As shown in thecircuit diagram of FIG. 12 , this arrangement facilitates a parallelbetween the windings of the same phase and a delta connection betweenpairs of windings of different phases, according to an embodiment.

FIG. 13 depicts a partial perspective view of the stator assembly 120focusing on a single stator terminal 170 disposed between two statorwindings 128. As shown here, and with continued reference to FIGS. 8-10, stator terminal 170 includes a main portion 172 received between theposts of the axial support member 134 normal to the longitudinal axis ofthe motor 100. Main portion 172 may be planar or include one or morearcuate segments having a similar curvature as the stator 122. A firstend of the main portion 172 (away from the circuit board 150) includes atang portion 174 that is folded over the outer surface of the mainportion 172. One or more cross-over wire portions 180 connecting theadjacent stator windings 128 located on two sides of the stator terminal170 are passed through the gap between the tang portion 174 and the mainportion 172 before the tang portion 174 is pressed against the mainportion 172. A second end of the main portion 172 (closer to the circuitboard 150) includes a pin 176 that is received within the correspondingperipheral opening 164 of the circuit board 150.

In an embodiment, start and finish ends of each of the stator windings128 are electrically coupled to its two adjacent stator terminal 170,and as discussed below in detail, connections between opposing statorwindings 128 of the same phase in a series of parallel connection, aswell as connections between stator windings 128 of different phases in awye or delta configuration, are facilitated via metal routings and/ortraces on the circuit board 150. This arrangement eliminates the needfor excessive routing of cross-over wire portions 180 that connect thestator windings 128 on the stator assembly 120.

In an embodiment, all stator windings 128 and cross-over wire portions180 may be wound on the stator 122 using a single continuous magnetwire. The single continuous magnet wire is wound fully for a designatednumber of turns on one stator tooth 126, passed through the tang portion174 of an adjacent stator terminal 170, wound fully on the adjacentstator tooth 126 for the designated number of turns, passed through asubsequent tang portion 174, and this process is continued until allstator windings 128 are fully wound with the designated number of turns.The two ends of the magnet wire may be wrapped around the tang portion174 of the same stator terminal 170.

In an embodiment, using a smaller diameter magnet wire increases theoverall slot fill and wire density within each slot. For example,winding the stator slots fully using a 19 AWG (American Wire Gauge)magnet wire (i.e., a 0.91 mm conductor diameter) may yield only a 51.14%slot fill per unit of area, because the large diameter of the magnetwire results in a less efficient overlay of the wires and larger airgapsbetween the wires. By contrast, winding the stator slots fully using a21.5 AWG magnet wire (i.e., a 0.68 mm conductor diameter) yields a58.61% slot fill. Similarly, winding the stator slots using a 23 AWGmagnet wire (i.e., a 0.57 mm conductor diameter) yields a 62.98% slotfill. Increasing slot fill and wire density results in a reduction inthe electrical resistance of the motor.

It is well understood that the number of turns of stator windings 128 oneach tooth 126 is correlated to the desired torque output of the motor.The more number of turns of the stator windings, the higher the torqueoutput of the motor. According, in order to increase slot fill andreduce electrical resistance of the motor while maintaining the desirednumber of turns of the stator windings 128 on each tooth 126, in anembodiment of the invention, two or more sets of stator windings havingrelatively smaller diameters are provided on each tooth and wound inparallel, as described herein in detail.

In an embodiment, as best seen in FIG. 13 , two or more sets of statorwindings 128 a and 128 b may be wound in parallel on each stator tooth126, with two or more cross-over wire portions 180 passes between theadjacent stator windings 128 a and adjacent stator windings 128 b. In anembodiment, a first layer of stator windings 128 a is initially wound onall stator teeth 126 as described above, and a second layer of statorwindings 128 b is wound on the same stator teeth 126 and in the samesequence on top of stator windings 128 a to create a parallel connectionbetween the respective stator windings 128 a and 128 on each statortooth 126. This may be accomplished using two separate continuous magnetwires, where a first magnet wire is wound on all stator teeth 126 asdescribed above in a first step to provide stator windings 128 a, and asecond magnet wire is wound on top of the first magnet wire on allstator teeth 126 in a second step to provide stator windings 128 b.Alternatively, the first and second sets of stator windings 128 a and128 b may be wound from the same continuous magnet wire.

FIG. 14A depicts a simple circuit diagram of the parallel sets of statorwindings 128 a and 128 b described above, according to an embodiment.FIG. 14B depicts a simple winding diagram of the parallel sets of statorwindings 128 a and 128 b described above, according to an embodiment. Itis noted that while these figures relate to an arrangement of two setsof stator windings per tooth, a higher number of parallel sets of statorwindings may be utilized.

This arrangement increases slot fill and reduce electrical resistance ofa motor for a given desired number of turns of the stator windings asrequired by the rated torque output of the motor. For example, in amotor where 19 number of turns of the stator windings is required toachieve a desired torque rating, two sets of stator windings 128 a and128 b may be wound on each stator tooth 126 as described above, each at19 number of turns and using a 21.5 AWG magnet wires. The parallelconfiguration of the 21.5 AWG stator windings 128 a and 128 on eachstator tooth 126 provides equivalent torque rating as a single set ofstator windings using a 19 AWG magnet wire at 19 number of turns, butwith a higher slot density and thus reduced electrical resistance.

FIGS. 15A and 15B depict partial cross-sectional views of a stator slot127 in which stator windings 128 are wound using 19 AWG and 21.5 AWGmagnet wires respectively, according to an embodiment. Sincecross-sectional area of a 19 AWG magnet wire is twice thecross-sectional area of 21.5 AWG magnet wire, as shown in these figures,38 total turns of the 21.5 AWG magnet wires (wound as two sets of 19turns in parallel) occupies substantially the same cross-sectional areaof the stator slots 127 as does 19 turns of a 19 AWG magnet wire.Accordingly, the same torque rating is achieved, even though theparallel arrangement of the stator windings using two 21.5 AWG magnetwires increases slot fill by approximately 15%. Further, the parallelarrangement of the stator windings using two 21.5 AWG magnet wiresreduces motor resistance by approximately 10%, improves power output byapproximately 5%, and improves thermal efficiency of the motor byapproximately 10%, as compared to a single set of 19 AWG magnet wire.

Similarly, in an embodiment, three sets of stator windings may be woundin parallel using 23 AWG magnet wires to further improve slot fill,reduce motor resistance, improve power output, and improve thermalefficiency of the motor. Table 1 below summarizes these findings.

TABLE 1 Coil Per Tooth Wire Gauge Wire Size Resistance Slot Fill 1 19AWG 0.91 mm 10.22 mOhms 51.14% 2 21.5 AWG  0.68 mm  9.18 mOhms 58.61% 323 AWG 0.57 mm 8.707 mOhms 62.98%

In an embodiment, the diameter of the magnet wire used for the first setof stator windings 128 a may be different from the diameter of themagnet wire used for the second set of stator windings. 128 b. Whilethis process may complicate the manufacturing process and require use oftwo winding machines for the same motor, it can provide an optimal slotfill. In yet another embodiment, the number of turns of the first set ofstator windings 128 a may be different from the number of turns of thesecond set of stator windings 128 b.

FIG. 16 depicts a partial axial view of the stator assembly 120,according to an embodiment. As discussed above, cross-over wires 180 areonly provided between adjacent stator windings 128, and not around thestator 120 between opposite windings of the same phase or windings ofdifferent phase. This provides an advantage in that the entire body ofthe stator terminals 170 can be contained within a first circularenvelope 190 defined by the outer surface of the stator 120. In anembodiment, the outermost parts of the stator terminals 170 form asecond circular envelope 192 that has a smaller diameter of the firstcircular envelope 190 defined by the outer surface of the stator 120.This is in contrast to prior art stator designs with in-line statorterminals, where, in order to accommodate a large number of cross-overwires on the end surface of the stator, the stator terminals are mountedon the outer edge of the stator and at least a portion of the statorterminal 170 project outwardly beyond the circumferential envelopedefined by the outer surface of the stator 120.

FIG. 17 depicts a side view of the stator 120 without the windings 128.Since cross-over wires 180 do not extend around the stator 120, thethickness of the stator core 124 may be reduced in comparison toconventional stators where cross-over wires are supported on the statorbetween opposite windings of the same phase or stator windings ofdifferent phases. In an embodiment, the thickness of the stator core 124is approximately in the range of 3.6 to 3.8 mm, preferably approximately3.7 mm, at its thickest points C at or near the center of the statorslots, and is approximately in the range of 3.0 to 3.4 mm, preferablyapproximately 3.1 to 3.2 mm, at its thinnest points D proximate thestator teeth 126. This allows the lengths of the stator teeth 126 besimilarly reduced and the inner diameter (ID) of the stator 120 to beincreased without sacrificing the area of the slots available fordisposition of stator windings 128. In an embodiment, the ratio of thestator inner diameter (ID) to its outer diameter (OD) is in the range ofapproximately 0.5 to 0.53, preferably approximately 0.51 to 0.52. In anexample, where the stator OD is 0.51 mm, the ID may be sized at 26 mm,allowing it to receive a rotor having an outer diameter of 25 mm.

In an embodiment, in order to maximize the area of the slots availablefor disposition of stator windings 128, the thickness E of the statortooth is reduced to approximately 2 times, and in particularly to 1.9 to2.1 times, the thickness D of the stator core 124. Further, as shown inFIGS. 18A to 18F below, the stator core 124 is shaped to improve thewiring layout and maximize the density of wire per volume within theslots. It is noted that in these figures, a 51 mm diameter stator isdepicted by way of example.

FIG. 18A depicts a side view of a conventional stator 200 with a statorcore 202 having a uniform thickness of approximately 4.8 mm and statorteeth 204 having a thickness of approximately 6.4 mm, according anembodiment. In this example, the stator ID is 24.5 mm. This arrangementprovides a slot area of approximately 20.5 mm2 for disposition of statorwindings. In an example, this stator may be wound with up to 21 turns of20.5 AWG magnet wire.

FIG. 18B depicts a side view of a stator 210 similar to stator 200 ofFIG. 18A, having a stator core 212 with a reduced uniform thickness ofapproximately 3.5 mm and stator teeth 214 having a thickness ofapproximately 6.4 mm, according to an embodiment. In this example, bymerely reducing the thickness of the stator core 212, the slot area isincreased to approximately 28 mm2. In an example, this stator may bewound with up to 33 turns of 20.5 AWG magnet wire.

FIG. 18C depicts a side view of side view of a stator 220 similar toFIG. 18B, having a stator core 222 with a uniform thickness ofapproximately 3.5 mm, but with stator teeth 224 having a reducedthickness of approximately 5.9 mm, according to an embodiment. In thisexample, by reducing the thickness of the stator teeth 224, the slotarea is increased to approximately 29 mm2. In an example, this statormay be wound with up to 33 turns of 20.5 AWG magnet wire.

FIG. 18D depicts a cross-sectional view of magnet wires 205 having anoptimized geometric layout for maximizing wire density of the statorwindings 128, according to an embodiment. In an embodiment of theinvention, given the same motor speed and/or torque requirements, thesame stator ID and OD, and the same winding machine and process, thislayout reduces the amount of air gap between the magnet wires 205. Assuch, this wiring layout allows a greater number of turns of the magnetwire, or a greater thickness of the magnet wire, to be wound for eachstator winding. FIGS. 18E and 18F described below aim to shape thestator core and/or winding to achieve this wire layout.

FIG. 18E depicts a side view of side view of a stator 230 similar toFIG. 18C but including a stator core 232 and stator teeth 234 shaped toimprove wire layout as shown in FIG. 18D in order to increase wiredensity of the stator windings 128. In an embodiment, stator 230includes a stator core 232 with a non-uniform thickness of approximately3.1 mm to 3.8 mm and stator teeth 224 having a non-uniform thickness ofapproximately 4.9 mm to 8.2 mm, according to an embodiment. In anembodiment, portion 236 of the stator core 232 and portion 238 of thestator teeth 234 are angled to achieve the wire layout as shown in FIG.18D. While this design in fact reduces the slot area to approximately 26mm2, it allows the stator 230 to be wound with up to 37 turns of 20.5AWG magnet wire.

FIG. 18F depicts a side view of side view of the stator 122, asdescribed in FIGS. 6 and 7 of this disclosure, according to anembodiment. Stator 122 is similar to stator 210 of FIG. 18E in somerespects, but the stator core 124 and stator teeth 126 are shaped tofurther increase the slot area while optimizing wire layout. In anembodiment, stator core 124 is provided with a non-uniform thickness ofapproximately 3.1 mm to 3.7 mm (i.e., distances C and D in FIG. 17 ),and each stator tooth 126 includes a substantially uniform thickness ofapproximately 35.9 mm (not including the tooth tips), according to anembodiment. In an embodiment, an angular portion 246 of the stator core124 extends at an angle θ1 from the main inner surface 248 of the statorcore 124, where θ1 is approximately in the range of 25 to 35 degrees,preferably approximately 30 degrees. Angular portion 246 forms an angleθ2 with the stator tooth 126 that is approximately in the range of 80 to100 degrees, preferably approximately 90 degrees. This designsubstantially achieves the desired wire layout of FIG. 18D but increasesthe slot area to approximately 29 mm2. This arrangement allows thestator 122 to be wound with up to 38 turns of 20.5 AWG magnet wire.

The results discussed above are summarized in Table 2 below:

TABLE 2 Stator 200 Stator 210 Stator 220 Stator 230 Stator 122 ToothWidth 6.6 mm 6.6 mm 5.9 mm 4.9-8.2 mm 5.9 mm Core Width 4.8 mm 3.5 mm3.4 mm 3.1-3.8 mm 3.1-3.7 mm ID 24.5 mm 24.5 mm 26 mm 26 mm 26 mm SlotArea 20.5 mm² 27.9 mm² 28.9 mm² 25.7 mm² 29.0 mm²

The maximum number of turns of different sized magnet wires for each ofthe stators described above are summarized in Table 3 below:

TABLE 3 Wire Size Stator 200 Stator 210 Stator 220 Stator 230 Stator 12218.0 AWG 10 T 14 T (+40%) 16 T (+60%) 17 T (+70%) 19 T (+90%) 19.5 AWG17 T 22 T (+29%) 25 T (+47%) 27 T (+59%) 30 T (+76%) 20.5 AWG 21 T 29 T(+38%) 33 T (+57%) 37 T (+76%) 38 T (+81%)

FIG. 19 depicts a comparative diagram showing the maximum power outputperforming of motor including a conventional stator (plot 250), stator122 interfacing a rotor having embedded magnets (plot 252), and stator122 interfacing a rotor having surface-mount magnets (plot 254). In thisdiagram, as is commonly understood by those skilled in the art, themotor power output increases as the motor stack length is increased. Inan embodiment, as shown in this diagram, the motor maximum power outputof at least 2000 watts may be achieved using a stator having a 35 mmlength and 51 mm outer diameter. This represents an improvement ofapproximately 25% for larger stack length and up to approximately 85%for a smaller stack length. When using the same stator with asurface-mount rotor design, the motor maximum power output of at least2200 watts may be achieved. This represents an improvement ofapproximately 35% for larger stack length and up to approximately 125%for a smaller stack length.

FIG. 20 depicts the side cross-sectional view of the motor 100 similarto FIG. 4 , additionally denoting an electrical envelope and a magneticenvelope of the motor 100, according to an embodiment.

In an embodiment, electrical envelope in this figure designates thetotal volume of the motor 100 where electrical and electro-magneticcomponents, including the circuit board 150 and all the wiringconnections between the stator windings 128, are located. The electricalenvelope is the volume of the motor that is peripherally bound by agenerally cylindrical boundary 302 extending along a radially outermostportion of the stator assembly 120 and having a diameter OD. Theelectrical envelope is further axially bound by a front plane 304 at afrontmost point of the stator assembly and the rotor, in this examplethe frontmost tip of the stator windings 128, and a rear plane 306 at arearmost point of the electro-magnetic part of circuit board 150, inthis example the surface of the circuit board 150 opposite the statorassembly 120. Electrical envelope has a length EL.

In an embodiment, the magnetic envelope is bound the generallycylindrical boundary 302, the front plane 304, a rear plane 308 at arearmost point of the stator windings 128. The magnetic envelope has alength ML that is smaller than the length EL.

FIG. 21 depicts a table comparing performance characteristics of themotor 100 to conventional BLDC motors. As demonstrated in this table,motor 100 is capable of producing higher maximum power output and highermotor constant for the given motor electrical envelope 300 thancomparable known BLDC motors.

Four examples of motor 100 are provided in this table includingdifferent numbers of parallel sets of stator windings per tooth. Themotor electrical envelope for these exemplary motors 100 are of the samegeometry (including stator diameter of 51 mm and electrical length LE of40 mm) and same volume (approximately 81,670 mm{circumflex over ( )}3 inthis example). The motor magnetic envelope for these exemplary motors100 are also of the same geometry (including stator diameter of 51 mmand magnetic length ML of 36.4 mm) and same volume (approximately 74,400mm{circumflex over ( )}3 in this example). By comparison, threeexemplary conventional motors are also included. The comparativeconventional BLDC motors have the same diameter (example 1), smallerdiameter (example 2), and larger diameter (example 3), but the lengthsof the respective motors are modified to maintain the same electricenvelope (approximately 81,670 mm{circumflex over ( )}3) and magneticenvelope (approximately 74,400 mm{circumflex over ( )}3) as the fourexemplary motors 100.

As can be seen, given the same motor electrical envelope and magneticenvelope described above, the motor maximum power output for motor 100increases from 1840 watts to 1895 watts (a 3% increase) when using twoparallel windings per tooth, to 1922 watts (a 4% increase) when usingthree parallel windings per tooth, and to 1950 watts (a 6% increase)when using four parallel windings per tooth. Any of these configurationsrepresents significant increases of maximum power output overconventional BLDC motors of the same size. It can be seen that theconventional BLDC motors having equivalent motor envelope and electricalenvelope to motor 100 produce maximum power output in the range ofapproximately 1000 watts to 1500 watts, i.e., approximately 18% to 45%less than motor 100 given the same size electrical envelope and samesize magnetic envelope.

Furthermore, the motor size (Km) constant of motor 100 increases fromwhen using two or more sets of parallel windings per tooth. Asunderstood by those skilled in the art, the Km constant is a parameterfor determining the efficiency and capacity of a motor. The Km constantis calculated as a function of the torque constant Kt and the resistanceof the motor R, Km=Kt/R2 or Km=Kt*I/P, where torque constant Kt is thetorque produced divided by motor current. Thus, the Km constantrepresents the capability of the motor to produce power normalized byresistance of the motor. In an embodiment, the Km constant of motor 100increases from 0.0762 N·m/√W to 0.0804 N·m/√W (a 5% increase) when usingtwo parallel windings per tooth, to 0.0826 N·m/√W (an 8% increase) whenusing three parallel windings per tooth, and to 0.0851 N·m/√W (a 10%increase) when using four parallel windings per tooth.

Any of these configurations represents a significant increase the Kmconstant over conventional BLDC motors having equivalent motor envelopeand electrical envelope to motor 100. It can be seen that the Kmconstants of the conventional BLDC motors having equivalent motorenvelope and electrical envelope to motor 100 are in the range ofapproximately 0.0471 to 0.0636 N·m/√W, i.e., approximately 18% to 50%less than the motor 100 given the same size electrical envelope and samesize magnetic envelope.

In an embodiment, to evaluate the motor performance irrespective of thesize of the motor, a ratio of the Km constant to the electrical envelopeand/or the magnetic envelope is provided.

In an embodiment, the ratio of the Km constant to the electricalenvelope of the motor is greater than 900 (N·m/√W)/m{circumflex over( )}3 in an embodiment, particularly greater than 940(N·m/√W)/m{circumflex over ( )}3 in an embodiment, more particularlygreater than 980 (N·m/√W)/m{circumflex over ( )}3, and even moreparticularly greater than 1020 (N·m/√W)/m{circumflex over ( )}3. Whenusing two or more sets of parallel coils per tooth, the ratio of the Kmconstant to electrical envelope of the motor is greater than 1080(N·m/√W)/m{circumflex over ( )}3 when using two parallel coils pertooth, greater than 1100 (N·m/√W)/m{circumflex over ( )}3 when usingthree parallel coils per tooth, and greater than 1140(N·m/√W)/m{circumflex over ( )}3 when using four parallel coils pertooth. By comparison, the ratios of the Km constant to electricalenvelope of conventional BLDC motors are at most 855(N·m/√W)/m{circumflex over ( )}3. This represents a performanceincrease, even when using merely a single set of coils per tooth onmotor 100.

In an embodiment, the ratio of the Km constant to the magnetic envelopeof the motor is greater than 810 (N·m/√W)/m{circumflex over ( )}3 in anembodiment, particularly greater than 850 (N·m/√W)/m{circumflex over( )}3 in an embodiment, and more particularly greater than 890(N·m/√W)/m{circumflex over ( )}3, and even more particularly greaterthan 930 (N·m/√W)/m{circumflex over ( )}3. When using two or more setsof parallel coils per tooth, the ratio of the Km constant to electricalenvelope of the motor is greater than 970 (N·m/√W)/m{circumflex over( )}3 when using two parallel coils per tooth, greater than 1000(N·m/√W)/m{circumflex over ( )}3 when using three parallel coils pertooth, and greater than 1030 (N·m/√W)/m{circumflex over ( )}3 when usingfour parallel coils per tooth. By comparison, the ratios of the Kmconstant to electrical envelope of conventional BLDC motors are at most780 (N·m/√W)/m{circumflex over ( )}3. This represents a performanceincrease, even when using merely a single set of coils per tooth onmotor 100.

FIG. 22 depicts a perspective view of the motor assembly 120 with thecircuit board 150 mounted thereon, according to an embodiment. In thisembodiment, instead of a power terminal block 154 as previouslydescribed, the circuit board 150 is provided with a series of (in thisexample three) discrete in-line motor terminals 402. In an embodiment,the motor terminals 402 are provided at an equidistant angularorientation, e.g., at 120 degrees apart. In an embodiment, each motorterminal 402 is radially in line with one of the stator terminals 170.In an embodiment, each motor terminal 402 is mounted on the circuitboard 150 via an insulating pad 404. In an embodiment, each motorterminal 402 includes a slanted portion, allowing an axis of the outertip of the motor terminal 402 to be positioned close to the outerperiphery of the circuit board 150.

FIG. 23 depicts a perspective view of the motor 100 including theabove-described motor terminal 402 arrangement, according to anembodiment. FIG. 24 depicts a perspective view of the motor 100 withpower module 42 mounted directed to the motor housing 110, according toan embodiment. In an embodiment, as previously described, power module42 includes six power switches (e.g., FETs or IGBTs) configured as athree-phase inverter switch for driving the motor 100. In an embodiment,power module 42 is disc-shaped with a circumference that isapproximately equal to or slightly smaller than the circumference of themotor housing 110. In an embodiment, power module 42 includes a powercircuit board 420 on which the power switches (not shown) are mounted,and an overmold structure 422 formed around the power switches. In anembodiment, power terminals 426 are further supported by the overmoldstructure 422 and are coupled to the battery receptacle 20 and/or theswitch module 38 to supply electric power to the power switches.

In an embodiment, motor housing 110 is provided with a series of supportposts 410 positioned to structurally support the power module 42. In anembodiment, the power module 42 is mounted above the support posts 410and secured to the posts 410 via fasteners 424. In an embodiment, eachsupport post 410 includes two legs 412 that project around the powermodule 42.

In an embodiment, end tips of the terminals 402 are received intocorresponding slots of the power circuit board 420. This allows thepower circuit board 420 to make a direct electrical connection to theterminals 402, and thus the stator windings 128, without a need forintermediary wires. Accordingly, this embodiments provides a two circuitboard arrangement disposed in parallel rearward of the stator assembly120, with circuit board 150 being located inside the motor housing 110and configured to support Hall sensors 151 and metal traces forinterconnection of the stator windings 128, and power circuit board 420being located outside the motor housing 110 and configured to supportthe power switches for driving the stator windings 128.

The above-described configuration of the motor 100, particularly incombination with the power module 42 mounted directly to the rear of themotor housing 110, provides high power in a small package highlydesirable for many power tool, industrial tools, motorized outdoorproducts, and home appliances. FIG. 1 described above provides anexample of a power tool that benefits from the high density advantagesof the motor 100 and power module 42. An example of an outdoor product,in this example an edger, utilizing the motor 100 and power module 42 ofthis disclosure, is described here with reference to FIGS. 25 and 26 .

FIG. 25 depicts a partial perspective view of an electric edger 500,according to an embodiment. In an embodiment, edger 500 includes ahousing 502, a blade guard 504 mounted on one side of the housing 502, alower handle portion 506 extending upwardly from the housing 502 at anangle, a tubular rod 508 extending from the lower handle portion 506 toa grip handle (not shown) accommodating a trigger switch (not shown)actuatable by a user, and wheels 510. A battery pack (not shown) may bemounted to the electric edger 500 near the grip handle to supplyelectric power. Operational and structural details of the edger 500 arebeyond the scope of this disclosure. Reference is made to U.S. Pat. No.5,325,928, which is incorporated herein by reference in its entirety,for details of an electric edger.

FIG. 26 depicts a perspective view of the electric edger 100 with afront portion of the housing 502 removed, according to an embodiment. Asshown here, the housing 502 is sized to house the motor 100 and thepower module 42 mounted to the rear of the motor housing 110. An outputof the motor 100, which is not visible in this figure, is rotationallycoupled, via a gear reduction mechanism and an output spindle, to acutting blade located within the blade guard 504. As such, in anembodiment, the power module 42 and the motor housing 110 are compactlycontained within the housing 502. In an embodiment, a microcontrollerfor controlling the switching operation of the power switches is alsodisposed within the housing 502. In an embodiment, the microcontrollermay be provided separately from the power module 42 or integrally on thecircuit board as the power switching within the power module 42. Assuch, the housing 502 accommodates all the electronics and controlfeatures required for driving the motor.

Example embodiments have been provided so that this disclosure will bethorough, and to fully convey the scope to those who are skilled in theart. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Terms of degree such as “generally,” “substantially,” “approximately,”and “about” may be used herein when describing the relative positions,sizes, dimensions, or values of various elements, components, regions,layers and/or sections. These terms mean that such relative positions,sizes, dimensions, or values are within the defined range or comparison(e.g., equal or close to equal) with sufficient precision as would beunderstood by one of ordinary skill in the art in the context of thevarious elements, components, regions, layers and/or sections beingdescribed.

The foregoing description of the embodiments has been provided forpurposes of illustration and description. It is not intended to beexhaustive or to limit the disclosure. Individual elements or featuresof a particular embodiment are generally not limited to that particularembodiment, but, where applicable, are interchangeable and can be usedin a selected embodiment, even if not specifically shown or described.The same may also be varied in many ways. Such variations are not to beregarded as a departure from the disclosure, and all such modificationsare intended to be included within the scope of the disclosure.

The invention claimed is:
 1. A power tool comprising: a housing; and amotor disposed within the housing, the motor including a stator assemblyand a rotor assembly including a rotor supporting a plurality of magnetsrotatable relative to the stator assembly, wherein the stator assemblyincludes a stator comprising a stator core and a plurality of statorteeth radially extending from the stator core and defining a pluralityof slots therebetween, a first plurality of stator windings wound on theplurality of stator teeth, and a second plurality of stator windingswound on the plurality of stator teeth such that, on each stator tooth,one of the first plurality of windings is provided electrically inparallel to one of the second plurality of stator windings, wherein thestator assembly further comprises a plurality of stator terminalsprovided between respective plurality of stator teeth in thecircumferential direction of the stator, wherein a first stator windingof the first plurality of stator windings and a second winding of thesecond plurality of stator windings that are wound on the same statortooth are commonly electrically coupled to two of the plurality ofstator terminals immediately adjacent said stator tooth to create aparallel connection between the first stator winding and the secondstator winding.
 2. The power tool of claim 1, wherein each of the firstwinding and the second winding starts on a first stator terminal of theplurality of stator terminals provided on a first side of said statortooth and terminates on a second stator terminal of the plurality ofstator terminals provided on a second side of said stator tooth.
 3. Thepower tool of claim 2, wherein the second winding is stacked on top ofthe first winding away from the stator core.
 4. The power tool of claim1, wherein the stator assembly comprises an end insulator provided at anaxial end of the stator to electrically insulate the stator from thefirst plurality of stator windings and the second plurality of statorwindings, the end insulator including one or more support members tosupport the plurality of stator terminals relative to the statorassembly.
 5. The power tool of claim 1, wherein the number of theplurality of stator teeth equals the number of the plurality of statorterminals.
 6. The power tool of claim 1, wherein the first plurality ofstator windings includes a first magnet wire that is securely routed incontact with the plurality of stator terminals as it is guided betweenthe plurality of stator teeth, and the second plurality of statorwindings includes a second magnet wire that is securely routed incontact with the plurality of stator terminals adjacent the first magnetwire as it is guided between the plurality of stator teeth.
 7. The powertool of claim 6, wherein each stator terminal includes a main portionextending approximately normal to a radial direction of the stator and atang portion that captures the first magnet wire and the second magnetwire against the main portion.
 8. The power tool of claim 6, whereinfirst magnet wire and the second magnet wire are formed using a singlecontinuous wire.
 9. The power tool of claim 1, wherein the stator coredefines a first circular envelope and outermost portions of theplurality of terminals define a second circular envelope that iscontained within the first circular envelope and has a smaller diameterthan the first circular envelope.
 10. The power tool of claim 1, furthercomprising a circuit board provided adjacent an axial end of the statorassembly, the circuit board being mounted on the plurality of statorterminals.
 11. The power tool of claim 10, wherein the stator assemblycomprises an end insulator provided at an axial end of the stator toelectrically insulate the stator from the first plurality of statorwindings and the second plurality of stator windings, the end insulatorincluding a plurality of support members to support the plurality ofstator terminals relative to the stator assembly along a longitudinaldirection of the motor, wherein the circuit board is mounted andfastened to the plurality of support members.
 12. The power tool ofclaim 10, wherein the circuit board comprises a plurality of magneticsensors arranged to magnetically interface with the rotor assembly and aplurality of conductive traces arranged to connect the plurality ofstator terminals.
 13. A brushless direct-current (BLDC) motorcomprising: a stator assembly; and a rotor assembly including a rotorsupporting a plurality of magnets rotatable relative to the statorassembly, wherein the stator assembly includes a stator comprising astator core and a plurality of stator teeth radially extending from thestator core and defining a plurality of slots therebetween, a firstplurality of stator windings wound on the plurality of stator teeth, anda second plurality of stator windings wound on the plurality of statorteeth such that, on each stator tooth, one of the first plurality ofwindings is provided electrically in parallel to one of the secondplurality of stator windings, wherein the stator assembly furthercomprises a plurality of stator terminals provided between respectiveplurality of stator teeth in the circumferential direction of thestator, wherein a first stator winding of the first plurality of statorwindings and a second winding of the second plurality of stator windingsthat are wound on the same stator tooth are commonly electricallycoupled to two of the plurality of stator terminals immediately adjacentsaid stator tooth to create a parallel connection between the firststator winding and the second stator winding.
 14. The BLDC motor ofclaim 13, wherein each of the first winding and the second windingstarts on a first stator terminal of the plurality of stator terminalsprovided on a first side of said stator tooth and terminates on a secondstator terminal of the plurality of stator terminals provided on asecond side of said stator tooth.
 15. The BLDC motor of claim 13,wherein the stator assembly comprises an end insulator provided at anaxial end of the stator to electrically insulate the stator from thefirst plurality of stator windings and the second plurality of statorwindings, the end insulator including one or more support members tosupport the plurality of stator terminals relative to the statorassembly.
 16. The BLDC motor of claim 13, wherein the number of theplurality of stator teeth which equals the number of the plurality ofstator terminals.
 17. The BLDC motor of claim 13, wherein the firstplurality of stator windings includes a first magnet wire that issecurely routed in contact with the plurality of stator terminals as itis guided between the plurality of stator teeth, and the secondplurality of stator windings includes a second magnet wire that issecurely routed in contact with the plurality of stator terminalsadjacent the first magnet wire as it is guided between the plurality ofstator teeth.
 18. The BLDC motor of claim 17, wherein each statorterminal includes a main portion extending approximately normal to aradial direction of the stator and a tang portion that captures thefirst magnet wire and the second magnet wire against the main portion.19. The BLDC motor of claim 13, wherein the stator core defines a firstcircular envelope and outermost portions of the plurality of terminalsdefine a second circular envelope that is contained within the firstcircular envelope and has a smaller diameter than the first circularenvelope.
 20. The BLDC motor of claim 13, wherein the first plurality ofstator windings and the second plurality of stator windings are togetherwound using a single continuous wire.
 21. The BLDC motor of claim 13,wherein the first plurality of stator windings and the second pluralityof stator windings have the same number of turns corresponding to atorque rating of the motor.